Sealing diaphragm and methods of manufacturing said diaphragm

ABSTRACT

Described is a method for manufacturing a diaphragm assembly through the use of injection molding. The method can avoid the use of PTFE as a chemically resistant coating. Further, the method can increase overall adherence of a polymer diaphragm to an insert through the use of an interference surface on at least the surface of a head of the insert.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

This Application claims from the benefit of U.S. Provisional ApplicationNo. 61/870,072, filed Aug. 26, 2013, titled “SEALING DIAPHRAGM ANDMETHODS OF MANUFACTURING SAID DIAPHRAGM,” U.S. Provisional ApplicationNo. 61/870,679, filed Aug. 27, 2013, titled “SEALING DIAPHRAGM ANDMETHODS OF MANUFACTURING SAID DIAPHRAGM,” U.S. Provisional ApplicationNo. 61/919,556, filed Dec. 20, 2013, titled “SEALING DIAPHRAGM ANDMETHODS OF MANUFACTURING SAID DIAPHRAGM,” and U.S. ProvisionalApplication No. 61/875,308, filed Sep. 9, 2013, titled “SEALINGDIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM,” the entirety ofeach of which is incorporated herein by reference.

BACKGROUND Field

The present disclosure relates generally to diaphragm assemblies for anaqueous solution, and methods for manufacturing said diaphragmassemblies.

SUMMARY

Disclosed herein are embodiments of a method for manufacturing adiaphragm assembly comprising forming an insert having a head and abody, wherein the head is located at one end of the body, forming atleast one interference surface on the insert, disposing the insertwithin a cavity configured for injection molding, wherein at least thehead is completely disposed within the cavity, and injection molding apolymer onto the insert, wherein the polymer is configured to adhere tothe head and the interference surface of the insert.

In some embodiments, forming the at least one interference surface cancomprise forming the at least one interference surface at approximatelythe center of the head of the insert. In some embodiments, forming atleast one interference surface can comprise forming a plurality ofinterference surfaces on the head of the insert. In some embodiments,forming at least one interference surface can comprise tapping at leastone hole into the head of the insert to form a blind tapped hole.

In some embodiments, the head can have a diameter greater than thediameter of the body. In some embodiments, at least five pairs ofinterference surfaces can be formed. In some embodiments, theinterference surface can be located on the outside of the head. In someembodiments, the interference surface can comprise threads or grooves.

In some embodiments, the polymer can be a PVDF polymer. In someembodiments, the PVDF polymer can comprise natural PVDF and KYNARULTRAFLEX® B. In some embodiments, the PVDF polymer can comprise 0.5% byweight natural PVDF and 99.5% by weight KYNAR ULTRAFLEX® B. In someembodiments, PTFE may not be used.

Also disclosed herein are embodiments of a two part diaphragm assemblycomprising an insert having a head and a body, wherein the head islocated at one end of the body, at least one interference surface formedon the insert, and an injection-molded polymer diaphragm configured toat least partially surround the head of the insert and interfere withthe interference surface.

In some embodiments, the polymer can be semi-transparent. In someembodiments, the polymer can be transparent.

In some embodiments, the interference surface can be locatedapproximately at the center of the insert. In some embodiments, theinsert can be metal. In some embodiments, the body of the insert cancomprise a thread. In some embodiments, the interference surface can bea blind tapped hole.

In some embodiments, the insert can further comprise at least oneadditional interference surface. In some embodiments, the additionalinterference surface can be configured as a through hole through thehead.

In some embodiments, the at least one interference surface can compriseat least five pairs of interferences surfaces. In some embodiments, theat least one interference surface can comprise four holes approximatelyequally spaced around the center of the insert and a fifth hole locatedat the center of the insert. In some embodiments, the interferencesurface can extend into the body.

In some embodiments, the polymer diaphragm can form an air tight sealaround the insert.

In some embodiments, the polymer diaphragm can be a PVDF polymerdiaphragm. In some embodiments, the PVDF polymer can comprise naturalPVDF and KYNAR ULTRAFLEX® B. In some embodiments, the PVDF polymer cancomprise 0.5% by weight natural PVDF, and 99.5% by weight KYNARULTRAFLEX® B. In some embodiments, PTFE may not be used.

In some embodiments, the interference surface can have a rounded end. Insome embodiments, the interference surface can be located on the outsideof the head. In some embodiments, the interference surface can comprisethreads or grooves.

Also disclosed herein are embodiments of a positive displacement pumpcomprising an input channel, an output channel, and a diaphragm assemblylocated between the input and output channel and configured to translateliquid from the input channel to the output channel, the assemblycomprising an insert having a head and a body, wherein the head islocated at one end of the body, at least one interference surface formedon the insert, and an injection-molded polymer diaphragm configured toat least partially surround the head of the insert and interfere withthe interference surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-E illustrate a diaphragm in the prior art.

FIGS. 2A-C illustrate a diaphragm in the prior art.

FIG. 3 illustrates a diaphragm system in the prior art.

FIGS. 4A-D illustrate a diaphragm in the prior art.

FIGS. 5A-E illustrate a diaphragm in the prior art.

FIGS. 6A-D illustrate an embodiment of a diaphragm according to thedisclosure.

FIGS. 7A-D illustrate an embodiment of an insert according to thedisclosure.

FIGS. 8A-B illustrate an embodiment of a diaphragm according to thedisclosure.

FIGS. 9A-B illustrate an embodiment of a diaphragm according to thedisclosure.

FIGS. 10A-D illustrate an embodiment of an insert according to thedisclosure.

FIGS. 11A-B illustrate an embodiment of a diaphragm according to thedisclosure.

FIGS. 12A-B illustrate an embodiment of an insert according to thedisclosure.

FIGS. 13A-B illustrate an embodiment of an insert according to thedisclosure.

FIGS. 14A-E illustrate an embodiment of a diaphragm according to thedisclosure.

FIG. 15 illustrates a method for manufacturing embodiments of adiaphragm according to the disclosure.

FIG. 16A-C illustrate manufacturing limitations of the above disclosedprior art.

DETAILED DESCRIPTION

Positive displacement pumps, such as metering pumps, can be used to pumpliquids at adjustable flow rates which are precise when averaged overtime. Metering pumps include diaphragm metering pumps, peristalticmetering pumps, piston pumps, etc. For metering pumps, motor drivenpumps, solenoid diaphragm pumps, and air operated diaphragm pumps canall be used

Pistons on a piston pump can move in and out of a chamber, causing thevolume of the chamber to become larger and smaller and creating avacuum. Low pressure causes liquid to enter and fill the chamber, andhigher pressure causes the liquid to be expelled from the changer. Ametering pump can be useful for measuring a precise volume of liquid ina specified time, thus having an accurate flow rate. Metering pumps canpump water, as well as other chemicals, solutions, and liquids. Meteringpumps can be used in high discharge pressure applications.

Disclosed herein are embodiments of a diaphragm assembly, and methodsfor manufacturing said diaphragm. The diaphragm assembly can be used in,for example, metering pumps, such as those described above. Thediaphragm assembly can further be used, for example, in conjunction withelevated or roof top water tanks. In some embodiments, the diaphragmassembly can be used to enable users to have water pressure in theirbathrooms and kitchens without expensive pumping equipment. The use ofthe diaphragm does not limit the disclosure.

In a diaphragm assembly, a diaphragm can be repeatedly moved back andforth to create a vacuum within a chamber to input and output a fluid,such as a gas or a liquid. Therefore, the diaphragm can experiencecyclical forces acting on it due to the repeated movement of thediaphragm, such as cyclical bending and cyclical pressure. If not formedproperly, the diaphragm may fail due to the cyclical forces acting onit. Accordingly, a diaphragm made from a material with high strength,flexibility, and/or toughness may be advantageous to prevent thediaphragm from fracturing, breaking, cracking, or failing in otheraspects. Further, the diaphragm can be manufactured so as to prevent thediaphragm from fracturing, breaking, cracking, or failing in otheraspects.

Additionally, a diaphragm assembly may be used in caustic environments,so a diaphragm can have high chemical resistance in some embodiments.For example, diaphragms can be resistant to chlorine and fluorine,although the chemical resistance is not limiting and the diaphragm canbe resistant to other chemicals as well.

Prior Diaphragms

Certain diaphragms are currently being used in the marketplace. However,upon a close analysis of the current diaphragms, significant problemscan be uncovered. A summary of some of the diaphragms currently in use,and their drawbacks, are described in detail below.

FIGS. 1A-E illustrates a diaphragm 100 used in the prior art. As shownin FIG. 1B, rubber coating 102 surrounds a metal insert 104. The rubbercoating is then covered by a layer of polytetrafluoroethylene (PTFE)106. The metal insert has a flat and disc-shaped head 108 which iscovered by the rubber coating 102. Further, Dacron®, or other similarfabric material, must cover the entire surface of the rubber 102 toincrease the overall strength. FIGS. 1A and C-E illustrate further viewsof the diaphragm

However, there are numerous drawbacks to the diaphragm described inFIGS. 1A-E. For example, the diaphragm utilizes numerous parts andmaterials (e.g. metal insert 104, rubber coating 102, PTFE 106). Thisrequires the purchase of numerous types of materials to manufacture thediaphragm. Further, the numerous parts and materials need to adhere toone another properly during operating of the diaphragm. Typically, anadhesive is used to connect all of the parts together. Adhesion canbecome a serious problem as repeated motion of the diaphragm 100 canlead to loosening of the adhesive, followed by failure, leading tobreakage of the overall device that the diaphragm is being used with.

Further, as mentioned above, PTFE needs to coat the entirety of therubber. If the PTFE 106 does not fully and properly coat the rubber 102,many types of chemicals will eat through the rubber 102, rendering thediaphragm useless.

The manufacturing process for making the diaphragm of FIG. 1 isdifficult as well. Specifically, manufacturing requires precisemachining of uniform thin walls. Further, the PTFE 106 must be free fromimperfections (such as wrinkles and voids), must cover the entiresurface of the rubber 102, and must be minimally thick (approximately0.014-0.016 inches). The rubber 102 is also required to be compressionmolded. Other manufacturing difficulties, such as sand blasting theinsert 104 for improved adhesion between layers also increases themanufacturing price. Because of the difficult manufacturingrequirements, even specialized companies have a rejection rate that canbe as high as 15%.

FIGS. 2A-C illustrate a different diaphragm used in the prior art. Asshown in FIG. 2A, the diaphragm 200 contains multiple pieces. A screw202 is surrounded by a material layer 204 and rests on a washer 206which in turn rests on a nut 208. The material layer 204 is similar tothe diaphragm described in FIG. 1 and contains a rubber, fabric,adhesive, and PTFE coating. The washer 206 is used to reinforce thematerial layer 204, and the nut 208 is used to hold the washer 206 inplace. FIGS. 2B-C illustrate views of the front and back of thisdiaphragm.

Similar to the diaphragm described with respect to FIG. 1, diaphragm 200has numerous drawbacks. For example, the diaphragm utilizes numerousparts and materials (e.g. screw 202, rubber coating and PTFE 204, wash206, and nut 208). This requires the purchase of numerous types ofmaterials to manufacture the diaphragm. Along the same lines, thenumerous parts and materials need to adhere to one another properly,typically with an adhesive. This can become a serious problem asrepeated motion of the diaphragm 200 can lead to loosening of theadhesive, followed by failure. Additionally, if the PTFE does not fullyand properly coat the rubber, many types of chemicals will eat throughthe rubber, rendering the diaphragm useless.

The manufacturing process for making the diaphragm of FIG. 2 isdifficult as well. For example, manufacturing of the prior artdiaphragms requires precise machining of uniform thin walls. Further,the PTFE must be free from imperfections (such as wrinkles and voids),must cover the entire surface of the rubber, and must be minimallythick. Because of the difficult manufacturing requirements, evenspecialized companies have a rejection rate that can be as high as 15%.Thus, numerous parts are wasted, increasing the overall cost of makingthe prior art diaphragms.

FIG. 3 illustrates a diaphragm system according to the prior art. Asshown, there is an inlet 302 for receiving a liquid and an outlet 304for discharging the liquid. Each of the inlet and outlet 302/304 have aone way check valve 306 to prevent the liquid from back flowing. Betweenthe inlet and outlet 302/304 are a pump head 308 and a diaphragm 310located on a washer 312. The washer 312 and/or diaphragm 310 is attachedto a piston 314 which produces suction between the inlet and outlet302/304. The piston is attached to a combination of pieces for movingthe piston, such as a yoke assembly 316, cam 318, motor shaft 320, andbearing 322. Diaphragms, such as those described with respect to theprior art figures, can be used as the diaphragm 310.

FIGS. 4A-D illustrate a different diaphragm in the prior art. FIGS. 4A-Billustrate a single piece diaphragm 402 made entirely out of PTFE. Inmost cases, the diaphragm 402 is also used with a backup washer (notshown). The diaphragm 402 can contain threading 404. FIGS. 4C-Dillustrate other views of the front and back of the diaphragm.

Again, there are significant problems with this type of diaphragm. PTFEis a very expensive material, and making a one piece diaphragm requiresmachining out of a large block or rod of the PTFE. This is a veryinefficient process, and much of the PTFE is wasted duringmanufacturing. The PTFE cannot be injection molded, and must bemachined. Further, to manufacture the single piece PTFE diaphragm,precise machining is needed to form the uniform walls, which is a verydifficult process. Moreover, this type of diaphragm is limited to asmaller overall diaphragm diameter due to limitations in machiningcapabilities. Even with a smaller diameter, distortion can still occurduring machining.

FIGS. 5A-D illustrate a different diaphragm in the prior art. As shownin FIG. 5B, the diaphragm 500 is made up of a threaded insert 502, awasher 504 with a threaded center hole, and a pair of PTFE sheets 506.The PTFE sheets 506 are 0.03 to 0.06 inches in thickness each, and aremanufactured by stamping using a compression forming tool. The threadedinsert 502 has a circular head 508 which is used to sandwich the PTFEsheets 506 between the circular head 508 and the washer 504. The surfaceof the circular head 508 is coated for increased chemical resistance.FIGS. 5A and C illustrate other viewpoints of the diaphragm and FIGS.5D-E illustrate other views of the diaphragm.

As with the other prior art diaphragms, diaphragm 500 has numerousdrawbacks associated with it. Diaphragm 500 requires multiple pieces andmaterial. In fact, numerous pieces need to be machine duringmanufacturing. Further, the diaphragm 500 relies on water tight/airtight seals between the threaded insert 502, PTFE sheets 506, and washer504. This water tight/air tight seal is a weak point which can bebroken. The seal can become a serious problem as repeated motion of thediaphragm 500 can lead to loosening of the seal, followed by failure.The diaphragm 500 also requires a separate chemical coating on the head508. In addition, the PTFE sheets 506 must be cut and formed using acompression tool, and a forming tool needs to be used as well.

Diaphragm Assemblies

FIGS. 6A-D illustrate an embodiment of a diaphragm assembly according tothe present disclosure. FIG. 6A shows a side cross section of adiaphragm assembly 600. As shown, the diaphragm assembly 600 can beformed from a two part system, though other parts can be used as welland the number of parts does not limit the disclosure. In someembodiments, there can be an insert 602 surrounded by a polymerdiaphragm 604. The insert 602 can contain at least one tapped hole 606,or other interference surface. The tapped hole 606 can be formed withscrew retention surfaces, or other types of interference surfaces, andthe type of tapping of the tapped hole 606 does not limit thedisclosure. In some embodiments, the tapped hole 606 can be centered onthe insert 602. In some embodiments, the tapped hole 606 can be locatedoutside of the center of the insert 602. In some embodiments, the tappedhole 606 can be a blind tapped hole. In some embodiments, more than onetapped hole 606 can be used.

The tapped hole 606 can extend at least 0.10, 0.15, 0.20, 0.25, 0.30,0.35, or 0.40 inches into the insert 602, though the dimensions are notlimiting. The tapped hole 606 can extend to a distance less than thelength of a head of the insert 602 or less than the total length of theinsert 602. The tapped hole 606 can extend at least 0.10 inches, and canbe less than 2 inches, although none of the dimensions limit thedisclosure. FIGS. 6B-C illustrate different viewpoints of an embodimentof a diaphragm assembly 600. FIG. 6D illustrates a side view of thediaphragm assembly 600, similar to FIG. 6A but without a cut out.

In some embodiments, the insert 602 and polymer diaphragm 604 can beapproximately 0.5, 1.0, 1.045, or 1.5 inches in length 610. The threadedportion 608 and can be at least approximately 0.1, 0.2, 0.3, 0.40, 0.5,or 0.6 inches in length, and the rest of the insert 602 and polymerdiaphragm 604 can be approximately 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.645,0.7, 0.8, 0.9, or 1 inches in length 612. As discussed below, in someembodiments, the insert 602 can have a narrowing portion 618 between thethreaded portion 608 and a head portion 616. The length of the polymerdiaphragm 604 to the beginning of the narrowing portion 618 can beapproximately 0.1, 0.2, 0.3, 0.4, 0.5, 0.560, 0.6, or 0.7 inches 614.None of the above dimensions are limiting.

FIGS. 7A-D illustrate an embodiment of an insert, such as the onedescribed above with respect to FIG. 6. The insert 702 can be, forexample, metals such as aluminum or brass. The insert 702 could also beformed from material such as, for example, polymers, ceramics, orcomposites of different materials. The type of material forming theinsert 702 does not limit the disclosure. In some embodiments, theinsert 702 can be formed from a single material or multiple materials.In some embodiments, the insert 702 can be formed by machining, thoughthe manufacturing method does not limit the disclosure.

As shown in FIG. 7A, in some embodiments the insert 702 can have a headportion 704, a body portion 706, a narrowing portion 708, and a threadedportion 710, though other portions can be used as well. The head portion704 can be generally circular in shape, though the shape is not limitingand can be, for example, rectangular, triangular, or ovaloid. In someembodiments, the head portion 704 can be wider than the other portions.For example, in some embodiments the head portion 704 is approximately1.0, 1.1, 1.149, 1.2, 1.3, 1.4, or 1.5 inches in diameter, or at least0.5 inches in diameter. In some embodiments, the diameter of the headportion 704 as compared to the diameter of a polymer diaphragm, such asdescribed above with respect to FIG. 6, can be approximately 1:1, 1:1.5,1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, or 1:10. In some embodiments,the head portion 704 can have a thickness of approximately 0.05, 0.1,0.120, 0.2, 0.3, 0.4, or 0.5 inches. However, the size of the headportion 704 does not limit the disclosure.

Further, the head portion 704 can have a tapped hole 712. This tappedhole 712 can be located in the center of the head portion 704, or not inthe center of the head portion 704. In some embodiments, the tapped hole712 can be approximately circular, though the shape of the tapped hole712 does not limit the disclosure. In some embodiments, the tapped hole712 can be a blind tapped hole. In some embodiments, the tapped hole 712can end in a flat surface, a rounded surface, or a pointed surface, andthe type of surface does not limit the disclosure. In some embodiments,the tapped hole 712 can be approximately 0.10, 0.15, 0.20, 0.25, 0.30,0.35, or 0.40 inches deep. In some embodiments, the tapped hole 712 canbe threaded. In some embodiments, more than one tapped hole 712 can beused.

The body portion 706 can follow the head portion 704. In someembodiments, the tapped hole 712 can enter the body portion 706,although in other embodiments it does not. The body portion 706 can begenerally cylindrical in shape, though the shape of the body portion 706does not limit the disclosure. In some embodiments, the body portion 706can have a diameter of approximately 0.1, 0.2, 0.3, 0.4, 0.492, 0.5,0.6, 0.7, or 0.8 inches. The distance from the far end of the headportion 704 to the opposite end of the body portion 706 can beapproximately 0.1, 0.2, 0.3, 0.4, 0.480, 0.5, 0.6, or 0.7 inches.

In some embodiments, following the body portion 706 can be the narrowingportion 708. The narrowing portion 708 can reduce the overall diameterof the insert 702. In some embodiments, the narrowing portion 708 canhave a generally smooth shape, and in some embodiments the narrowingportion 708 has a step wise shape. The shape of the narrowing portion708 does not limit the disclosure. The distance from the far end of thehead portion 704 to the opposite end of the narrowing portion 708 can beapproximately 0.1, 0.2, 0.3, 0.4, 0.5, 0.565, 0.6, 0.7, 0.8, 0.9, or 1.0inches. In some embodiments, the total length of the insert 702 can beapproximately 0.5, 0.7, 0.9, 0.965, 1.0, 1.5, or 2 inches. The totallength of the insert 702 does not limit the disclosure. In someembodiments, the insert 702 may not have a narrowing portion 708, andthe body portion 706 can flow directly into the threaded portion 710.

In some embodiments, the portion following the narrowing portion 708 canbe the threaded portion 710. In some embodiments, the threaded portion710 can be an interference surface. The threaded portion 710 can have adiameter less than both the head portion 704 and the body portion 706,though this does not limit the disclosure. The threaded portion can beconfigured to mate with a pump, such as the pump used in the prior artshown as FIG. 3. However, the attachment of the insert 702 to a pumpdoes not limit the disclosure, and any type of attachment means can beused. FIGS. 7B-D illustrate different viewpoints of the insert 702.

FIGS. 8A-B show an embodiment of a disclosed diaphragm assembly, such asthe ones described above. As shown, the diaphragm assembly 800 can begenerally circular shaped. The polymer diaphragm 804 can be located bothabove and below a head portion 704 of the insert 802 so that the head isfully encompassed by the polymer diaphragm. As shown in FIGS. 8A-B, thehead portion 704 of the insert 802 cannot be seen from the outside. Insome embodiments, the polymer diaphragm 804 can be generally flat onethe back side 808. In some embodiments, there can be some curvature orstep features on the back side 808.

On the front side 810, the outer circumference 810 of the polymerdiaphragm 804 can have a first thickness. Moving towards the center, thepolymer diaphragm 804 can have a step up 812 to a second thickness 814.There can then be a second step up 816 occurring at the insert 802, sothat the head of the insert 802 is fully covered. In some embodiments,the front side 810 can have a generally smooth taper.

As described above, a tapped hole can be formed in the insert. Thistapped hole can be advantageous for increasing the overall adherence ofthe polymer diaphragm onto the insert. The polymer diaphragm can wraparound the head of the insert as well as inserting into the tapped holeduring manufacturing. If a tapped hole is used, the polymer diaphragmhas more surface area to adhere to the insert. In some embodiments, thetapped hole is threaded, or given another type of interference surface,providing for even more surface area for adhesion. Further, diaphragmthat is inserted into the tapped hole can exert force on the sides ofthe tapped hole, thereby increasing the adhesion between the polymerdiaphragm and the insert. The increased adhesion allows for largerinsert heads to be used. Unexpectedly, the use of at least one tappedhole can allow for the polymer diaphragm to be manufactured usinginjection molding, instead of compression molding, which can beadvantageous for manufacturing.

FIGS. 9A-B illustrate an embodiment of a diaphragm assembly according tothe present disclosure. FIG. 9A illustrates a cut-out side view of anembodiment of the diaphragm assembly 900. As shown, the diaphragmassembly 900 can be formed from a two part system, though other partscan be used as well and the number of parts does not limit thedisclosure. In some embodiments, there can be an insert 902 surroundedby a polymer diaphragm 904. The insert 902 can contain at least onetapped hole 906. The tapped hole 906 can be formed with screw retentionsurfaces, or other types of interference surfaces, and the type oftapping of the tapped hole 906 does not limit the disclosure. In someembodiments, the tapped hole 906 can be centered on the insert 902. Insome embodiments, the tapped hole 906 can be located outside of thecenter of the insert 902. In some embodiments, the tapped hole 906 canbe a blind tapped hole. In some embodiments, more than one tapped hole906 can be used. The tapped hole 906 can extend approximately 0.10,0.15, 0.20, 0.25, 0.30, 0.35, or 0.40 inches into the insert 902, thoughthe dimensions are not limiting.

In some embodiments, at least one bonding hole 908 can be formed in theinsert 902. In some embodiments, a plurality of bonding holes 908 can beformed in the insert. Specifically, the bonding holes 908 can be formedat the head 910 of the insert 902. The bonding holes 908 can passcompletely through the head 910, or can pass only partially through thehead 910. The bonding holes 908 can be on either side of the head 910,or can be on both sides of the head 910 if they only partially passthrough the head 910. In some embodiments, the bonding holes 908 canhave a similar shape and diameter as the tapped hole 906. In someembodiments, the 908 can include interference surfaces, such as tapping.In some embodiments, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 bonding holes 908can be used. In some embodiments, at least 1 bonding hole 908 can beused, though the number of bonding holes 908 is not limiting. In someembodiments, the bonding holes 908 can be spaced evenly around the head910. In some embodiments, the bonding holes 908 can be located generallyrandom around the head 910.

As shown in FIG. 9B, the polymer diaphragm 904 can have a diameter ofapproximately 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 4.800, 5, 5.5, or 6inches. In some embodiments, the polymer diaphragm 904 can have athickness of approximately 0.05, 0.100, 0.15, 0.2, 0.25, 0.3, or 0.4inches at its far circumference. In some embodiments, the diaphragm 904can have a thickness of at least 0.01, 0.05, 0.15, 0.2, or 0.25 inchesthick, although the thickness is not limiting.

FIGS. 10A-D illustrate an embodiment of an insert, such as the onedescribed above with respect to FIG. 9. The insert 1002 can be, forexample, metals such as aluminum or brass. The insert 1002 could also beformed from material such as, for example, polymers, ceramics, orcomposites of different materials. The type of material forming theinsert 1002 does not limit the disclosure. In some embodiments, theinsert 1002 can be formed from a single material or multiple materials.In some embodiments, the insert 1002 can be formed by machining, thoughthe manufacturing method does not limit the disclosure.

As shown in FIG. 10A, in some embodiments the insert 1002 can have ahead portion 1004, a body portion 1006, a narrowing portion 1008, and athreaded portion 1010, though other portions can be used as well. Thehead portion 1004 can be generally circular in shape, though the shapeis not limiting and can be, for example, rectangular, triangular, orovaloid. In some embodiments, the head portion 1004 can be wider thanthe other portions. For example, in some embodiments the head portion1004 is approximately 1.5, 1.6, 1.7, 1.8, 1.9, 1.919, 2.0, 2.1, 2.2, or2.3 inches in diameter.

Further, the head portion 1004 can have a tapped hole 1012. This tappedhole 1012 can be located in the center of the head portion 1004, or notin the center of the head portion 1004. In some embodiments, the tappedhole 1012 can be approximately circular, though the shape of the tappedhole 1012 does not limit the disclosure. In some embodiments, the tappedhole 1012 can end in a flat surface, a rounded surface, or a pointedsurface, and the type of surface does not limit the disclosure. In someembodiments, the tapped hole 1012 can be a blind tapped hole. In someembodiments, the tapped hole 1012 can be approximately 0.1, 0.2, 0.25,0.3, 0.4, 0.5, or 0.6 inches deep. In some embodiments, the tapped hole1012 can be threaded. In some embodiments, more than one tapped hole1012 can be used.

In some embodiments, the insert 1002 can have at least one bonding hole1014. In some embodiments, the insert 1002 can have a plurality ofbonding holes 1014. The insert 1002 can have 1, 2, 3, 4, 5, 6, 7, 8, 9,or 10 bonding holes 1014. The bonding holes 1014 can have a diameter ofabout 0.05, 0.10, 0.15, 0.20, 0.30, 0.40, or 0.50 inches. If there ismore than one bonding hole 1014, the bonding holes 1014 can be equallyspaced apart from one another. In some embodiments, the bonding holes1014 may not be equally spaced apart from one another. In someembodiments, the bonding holes 1014 are centered 1016 around the tappedhole 1012 at a diameter of 1.0, 1.1, 1.2, 1.3, 1.4, 1.41, 1.5, 1.6, or17 inches from one another. In some embodiments, the bonding holes 1014go all the way through the head portion 1004 of the insert 1002, and inother embodiments the head portion 1004 go partially through the headportion 1004.

The body portion 1006 can follow the head portion 1004. In someembodiments, the tapped hole 1012 can enter the body portion 1006,although in other embodiments it does not. The body portion 1006 can begenerally cylindrical in shape, though the shape of the body portion 706does not limit the disclosure. In some embodiments, the body portion1006 can have a diameter of approximately 0.1, 0.2, 0.3, 0.4, 0.492,0.5, 0.6, 0.7, or 0.8 inches. The distance from the far end of the headportion 1004 to the opposite end of the body portion 1006 can beapproximately 0.1, 0.2, 0.3, 0.4, 0.480, 0.5, 0.6, or 0.7 inches.

In some embodiments, following the body portion 1006 can be thenarrowing portion 1008. The narrowing portion 1008 can reduce theoverall diameter of the insert 1002. In some embodiments, the narrowingportion 1008 can have a generally smooth shape, and in some embodimentsthe narrowing portion 1008 has a step wise shape. The shape of thenarrowing portion 1008 does not limit the disclosure. The distance fromthe far end of the head portion 1004 to the opposite end of thenarrowing portion 1008 can be approximately 0.1, 0.2, 0.3, 0.4, 0.5,0.565, 0.6, 0.7, 0.8, 0.9, or 1.0 inches. The total length of the insert1002 can be approximately 0.5, 0.6, 0.7, 0.8, 0.9, 0.965, 1.0, 1.2, 1.3,1.4, or 1.5 inches. In some embodiments, the insert 1002 may not have anarrowing portion 1008, and the body portion 1006 can flow directly intothe threaded portion 1010.

In some embodiments, the portion following the narrowing portion 1008can be the threaded portion 1010. In some embodiments, the threadedportion 1010 can be an interference surface. The threaded portion 1010can have a diameter less than both the head portion 1004 and the bodyportion 1006, though this does not limit the disclosure. The threadedportion 1010 can have a diameter of approximately 0.1, 0.2, 0.3, 0.4,0.492, 0.5, 0.6, or 0.7 inches. The threaded portion can be configuredto mate with a pump, such as the pump used in the prior art shown asFIG. 3. However, the attachment of the insert 1002 to a pump does notlimit the disclosure, and any type of attachment means can be used.FIGS. 10B-D illustrate different viewpoints of the insert 1002.

FIGS. 11A-B show pictures of an embodiment of a disclosed diaphragmassembly, such as the ones described above. As shown, the diaphragmassembly 1100 can be generally circular shaped. The polymer diaphragm1104 can be located both above and below a head portion of the insert1102 so that the head is fully encompassed by the polymer diaphragm1104. As shown in FIGS. 11A-B, the head portion 704 of the insert 1102cannot be seen from the outside. In some embodiments, the polymerdiaphragm 1104 can enter a tapped hole 1118 of the insert 1102,additionally securing the polymer diaphragm 1104 to the insert 1102. Insome embodiments, the polymer diaphragm 1104 can enter bonding holes1106 of the insert 1102, thereby additionally securing the polymerdiaphragm 1104 to the insert 1102. In some embodiments, the polymerdiaphragm 1104 can be generally flat one the back side 1108 as shown inFIG. 11B. In some embodiments, there can be some curvature or stepfeatures on the back side 1108.

On the front side shown in FIG. 11A, the outer circumference 1110 of thepolymer diaphragm 1104 can have a first thickness. Moving towards thecenter, the polymer diaphragm 1104 can have a step up 1112 to a secondthickness 1114. There can then be a second step up 1116 occurring at theinsert 1102, so that the head of the insert 1102 is fully covered. Insome embodiments, the front side can have a generally smooth taper.

As described above, the use of a tapped hole and at least one bondinghole can be used on the insert. These holes can be advantageous forincreasing the overall adherence of the polymer diaphragm onto theinsert. If a tapped hole is used, the polymer diaphragm has more surfacearea to adhere to the insert. The polymer diaphragm can wrap around thehead of the insert as well as inserting into the tapped hole duringmanufacturing. In some embodiments, the tapped hole is threaded, orgiven another type of interference surface, providing for even moresurface area for adhesion. Further, the tapped hole can apply pressureto polymer diaphragm that is inserted into the hole, thereby increasingthe adhesion between the polymer diaphragm and the insert.

In addition, the bonding holes allows for the polymer to fully connectaround the insert, such as in FIG. 9B, thus entrapping the insert withinthe polymer. Therefore, the polymer has increased strength and bindingto the insert. The increased adhesion allows for larger insert heads tobe used. Unexpectedly, the use of the additional holes can allow for thepolymer diaphragm to be manufactured using injection molding, instead ofcompression molding.

Externally Threaded Insert

In some embodiments, the polymer diaphragm assembly can contain aninsert with an interference surface on the external surface of head. Insome embodiments, the insert with the interference surface on theoutside surface of the head can be used in conjunction with a threadedblind hole, such as those described above. In some embodiments, theinsert with the interference surface on the outside surface of the headcan be used instead of a threaded blind hole. For example, theinterference surface can be a recessed surface, or multiple recessedsurfaces, separated by surfaces having a greater maximum dimension ordiameter. In some embodiments, the interference surface can be recessedwith respect to adjacent portions of the head. In some embodiments, theinterference surface on the outside surface of the head can beadvantageous for a smaller diameter diaphragm assembly which can beused, for example, with low flow rates.

FIGS. 12A-B illustrates an embodiment of an insert 1202 having a headportion 1204, a body portion 1206, a narrowing portion 1208, and athreaded portion 1210. The head portion 1204 can be generally circularin shape, though the shape does not limit the disclosure.

In some embodiments, the head portion 1204 can be wider than the otherportions. For example, in some embodiments the head portion 1204 isapproximately 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.62, 0.7, 0.8, 0.9, 1.0,1.1, 1.149, 1.2, 1.3, 1.4, or 1.5 inches in diameter. In someembodiments, the diameter of the head portion 1204 as compared to thediameter of a polymer diaphragm, can be approximately 1:1, 1:1.5, 1:2,1:3, 1:3.45, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, or 1:10. In some embodiments,the head portion 1204 has a thickness of approximately 0.05, 0.1, 0.120,0.2, 0.3, 0.4, or 0.5 inches. The head portion 1204 can extend about0.1, 0.2, 0.270, 0.3, 0.35, 0.4, 0.5, or 0.6 inches away from the bodyportion 1206. However, the size of the head portion 1204 is notlimiting.

Further, the head portion 1204 can have a grooved interference surface1212 on its outer surface. This grooved interference surface 1212 can beused, for example, with or without a tapped hole. The groovedinterference surface 1212 can be, for example, a boss protruding out ofthe body portion 1206 of the insert 1202. This grooving can provide fora further mechanical bond between the insert 1202 and a polymerdiaphragm that can be located around the insert 1202. The polymerdiaphragm can be injection molded so that the polymer extends into thegrooved interference surface 1212. The grooving can extend fully orpartially around the circumference of the insert 1202. In someembodiments, one grooved interference surface 1212 can be used on thehead portion 1204. In some embodiments, a plurality of groovedinterference surfaces 1212 can be used. The grooved interference surface1212 can have a groove depth of 0.1, 0.2, 0.3, 0.4, 0.460, 0.5, 0.6, or0.7 inches. The grooved interference surface 1212 can have grooveshaving a thickness of 0.03, 0.04, 0.05, 0.06, 0.062, 0.07, 0.08, or 0.09inches.

The body portion 1206 can follow the head portion 1204. The body portion1206 can be generally cylindrical in shape. In some embodiments, thebody portion 1206 can have a diameter of approximately 0.1, 0.2, 0.3,0.4, 0.492, 0.5, 0.6, 0.7, or 0.8 inches. The distance from the far endof the head portion 1204 to the opposite end of the body portion 1206can be approximately 0.1, 0.2, 0.3, 0.4, 0.480, 0.5, 0.6, or 0.7 inches.In some embodiments, following the body portion 1206 can be thenarrowing portion 1208. The narrowing portion 1208 can reduce theoverall diameter of the insert 1202. In some embodiments, the narrowingportion 1208 has a generally smooth shape, and in some embodiments thenarrowing portion 1208 has a step wise shape. The distance from the farend of the head portion 1204 to the opposite end of the narrowingportion 1208 can be approximately 0.1, 0.2, 0.3, 0.4, 0.5, 0.565, 0.6,0.7, 0.8, 0.9, or 1.0 inches. In some embodiments, the total length ofthe insert 1202 can be approximately 0.5, 0.7, 0.9, 0.965, 1.0, 1.5, or2 inches. The total length of the insert 1202 does not limit thedisclosure. In some embodiments, the insert 1202 may not have anarrowing portion 1208, and the body portion 1402 can flow directly intothe threaded portion 1210.

In some embodiments, the portion following the narrowing portion 1208can be the threaded portion 1210. In some embodiments, the threadedportion 1210 can be an interference surface. The threaded portion 1210can have a diameter less than both the head portion 1204 and the bodyportion 1206. The threaded portion can be configured to mate with apump, such as the pump used in the prior art shown as FIG. 3. However,the attachment of the insert 1202 to a pump does not limit thedisclosure, and any type of attachment means can be used. FIG. 12Billustrates a top down viewpoint of the insert 1202.

FIGS. 13A-B illustrate an embodiment of an insert 1302 having a threadedinterference surface 1312. As shown in FIG. 13A, the head portion 1304can have a threaded interference surface 1312 on its outer surface thatis a thread. This threaded interference surface 1312 can be used, forexample, with our without a tapped hole. The threaded interferencesurface 1312 can be, for example, a boss protruding out of the insert1302 and having a threaded surface. This threading can provide for amechanical bond between the insert 1302 and a polymer diaphragm that islocated on top. In some embodiments, the threaded interference surface1312 can extend the whole length of the head portion 1304. In someembodiments, the threaded interference surface 1312 only extendspartially down the length of the head portion 1304. In some embodiments,one threaded interference surface 1312 can be found on the head portion1304. In some embodiments, a plurality of threaded interference surfaces1312 can be used. Similar to the above FIGS. 12A-B, the insert 1302 canhave a body portion 1306, a narrowed portion 1308, and a threadedportion 1310.

The threaded interference surface 1312 can have a thread depth of 0.1,0.2, 0.3, 0.4, 0.436, 0.5, 0.6, or 0.7 inches. The threaded interferencesurface 1312 can have a ¼, 5/16, ⅜, 7/16, ½, 9/16, ⅝, ¾, or ⅞ thread,but the size of the thread is not limiting. FIG. 13B illustrates a topdown viewpoint of the insert 1302 having threaded interference surface1312.

FIGS. 14A-E illustrate an embodiment of a diaphragm assembly accordingto the present disclosure. FIG. 14A shows a side cross section of adiaphragm assembly 1400. As shown, the diaphragm assembly 1400 can beformed from a two part system, though other parts can be used as welland the number of parts does not limit the disclosure. In someembodiments, there is can be an insert 1402 surrounded by a polymerdiaphragm 1404. The insert 1402 can contain an outer interferencesurface 1406, such as those described with respect to FIGS. 12 and 13.FIGS. 14B-C illustrate different viewpoints of an embodiment of adiaphragm assembly 1400. FIG. 14D illustrates a side view of thediaphragm assembly 1400 without a cut out.

FIG. 14E illustrates a side viewpoint of an embodiment of a polymerdiaphragm 1404. In some embodiments, the polymer diaphragm 1404 can haveat least one ring 1420 located on a surface of the diaphragm 1404. Insome embodiments, the polymer diaphragm 1404 can have a second ring 1422located on a surface of the diaphragm 1404 opposite ring 1420. In someembodiments, rings 1420/1422 are directly opposite one another. In someembodiments, rings 1420/1422 are not directly opposite one another. Insome embodiments, the rings 1420/1422 can have a radius of 0.005, 0.01,0.02, 0.03, 0.04, or 0.05 inches. In some embodiments, the rings1420/1422 can be the same size. In some embodiments, one ring can belarger than the other ring.

In some embodiments, the insert 1402 and polymer diaphragm 1404 can beapproximately 0.5, 1.0, 1.415, or 1.5 inches in length. The threadedportion 1408 can be at least approximately 0.1, 0.2, 0.3, 0.40, 0.5,0.550 or 0.6 inches in length, and the rest of the insert 1402 andpolymer diaphragm 1404 can be approximately 0.1, 0.2, 0.3, 0.4, 0.5,0.6, 0.645, 0.7, 0.8, 0.9, or 1 inches in length. In some embodiments,the insert 1402 can have a narrowing portion 1418 between the threadedportion 1408 and a head portion 1416. The length of the polymerdiaphragm 1404 to the beginning of the narrowing portion 1418 can beapproximately 0.1, 0.2, 0.3, 0.4, 0.5, 0.560, 0.6, or 0.7 inches. Noneof the above dimensions limit the disclosure. The diameter of thepolymer on top of the interference surface 1406 can be about 0.3, 0.4,0.5, 0.6, 0.62, 0.7, 0.8, or 0.9 inches. The diameter of the polymerdiaphragm 1404 can be about 1.5, 1.8, 2.0, 2.1, 2.140, 2.3, or 2.5inches.

As would be understood by a person skilled in the above from the abovedescription, the interference surfaces described herein can be formedhaving either axial (such as shown in FIGS. 6-11) or radial (such asshown in FIGS. 12-14) depth, or both, and the direction of theinterference surface does not limit the disclosure.

Polymer Diaphragm

In some embodiments, the diaphragms described above can be made of apolymer, or a combination of polymers. For example, the diaphragm can bemade of polyvinylidene fluoride (PVDF). PVDF is a highly non-reactivethermoplastic fluoropolymer which is polymerized with vinylidenedifluoride. PVDF is strong and extremely resistant to solvents, acids,bases, and heat. Further, PVDF has a relatively low melting point ofapproximately 177° C., so it can be easier to melt than other polymers.PVDF has a glass transition temperature of about −35° C., and can befrom around 50-60% crystalline. In some embodiments, PVDF can bemechanically stressed to orient its molecular chains.

In some embodiments, the polymer used, such as PVDF, can be transparentor semi-transparent. By having a transparent or semi-transparentpolymer, a user could visually check to see if delamination is occurringbetween the insert and the polymer. Additionally, a user could visuallycheck whether particles were being formed through, for example,abrasion. This could allow a user to determine when to replace adiaphragm. However, non-transparent polymers could also be used, and theopacity of the polymer does not limit the disclosure unless otherwisestated.

In some embodiments, specific PVDF compositions can be used. Forexample, KYNAR ULTRAFLEX® B (ULTRAFLEX) can be used alone, or inconjunction with natural PVDF, to form a diaphragm. Natural PVDF can be,for example, KYNAR PVDF 700 SERIES. ULTRAFLEX is a semi-crystallinecopolymer of vinylidene fluoride and a hexafluoropropylene. It is ahighly flexible material, and has high toughness and weatherability.Further, ULTRAFLEX is extremely chemically resistant, and can be used indifferent corrosive environments. ULTRAFLEX is a PVDF polymer having adensity of 1.77 grams per cubic centimeter, a water absorption of0.030%, a tensile yield strength of 6.50 MPa, an elongation at break ofgreater than 50%, an elongation at yield of 20%, a tensile modulus of0.0800 GPa, a melting point of 101° C., a deflection temperature at 1.8MP of 46.0°, an oxygen index of 40%, and a melt viscosity in a rangebetween 12.0 and 20.0 kilopoise when said melt viscosity is tested at232° C. according to American Standard Test Method D3835.

In some embodiments, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, or0.9% by weight natural PVDF can be mixed with ULTRAFLEX. In someembodiments, greater than 0.1%, greater than 0.5%, or greater than 1.0%,by weight, of natural PVDF can be mixed with ULTRAFLEX. In someembodiments, less than 1.0%, or less than 2.0% by weight of natural PVDFcan be added.

In some embodiments, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, or 9% by weightnatural PVDF can be mixed with ULTRAFLEX. In some embodiments, greaterthan 1%, greater than 5%, or greater than 10.0%, by weight, of naturalPVDF can be mixed with ULTRAFLEX. In some embodiments, less than 10.0%,or less than 20.0% by weight of natural PVDF can be added.

The addition of ULTRAFLEX can change the overall properties of thepolymer. For example, without the natural PVDF, ULTRAFLEX can harden tooquickly, forming waves in the finished product. Adding the natural PVDFcan increase the flow rate of the material while injection molding, andcan smooth the overall shape of a final manufactured piece. Byincreasing the flow rate, more control can be maintained over the flowof the polymer during injection molding.

Moreover, ULTRAFLEX is a relatively flexible material, but is not ashard as may be needed. On the other hand, PVDF has relatively high Shorehardness. Therefore, the addition of natural PVDF to ULTRAFLEX canincrease the overall hardness of the ULTRAFLEX, which can also make theULTRAFLEX it tougher. For example, without the use of natural PVDF,ULTRAFLEX by itself heavily abrades when used with rollers. However, toomuch natural PVDF may cause the ULTRAFLEX to lose its flexibility,making the diaphragm more rigid, which can lead to faster breakageduring repeated stress cycles.

The incorporation of natural PVDF into ULTRAFLEX can allow for thediaphragm to be used in pressure systems that have 50% or more pressurethan ULTRAFLEX alone. For example, a diaphragm made of the combinationmay be used in pressures of 150 psi or greater, whereas previousdiaphragms, such as those disclosed above, have a max pressure of 100psi.

The addition of lower percentages of natural PVDF will not significantlyaffect the opacity of the finished diaphragm, thereby allowing a user tocontinue to be able to see through. Further, the chemical resistanceproperties of ULTRAFLEX are maintained, as the addition of natural PVDFwill also not affect these properties.

In some embodiments, the entire diaphragm assembly can be made fromPVDF, such as those described above. In some embodiments, otherpolymers, such as polypropylene or polyvinyl chloride can be used. Insome embodiments, PTFE is not used in the diaphragm.

The above described polymers do not limit the disclosure, and otherpolymers that can be injection molded can also be used. Differentpolymers can be chosen based on their resistance to specific chemicalenvironments in when the diaphragm system may be used in. For example, apolymer resistant to chlorine or fluorine may be used in conjunctionwith water treatment facilities.

Manufacturing of Diaphragm Assembly According to Embodiments of theDisclosure

In some embodiments, a diaphragm assembly can be manufactured at leastpartially through the use of injection molding. Injection molding hasnot been performed for diaphragm assemblies, such as the prior art,because of substantial difficulties, as further described below.Embodiments of the diaphragm assembly described above have substantiallyreduced the difficulties in forming a diaphragm assembly throughinjection molding.

Typically, diaphragms made in the prior art use compression molding toform any polymers. However, compression molding can have seriousdrawbacks, such as poor product consistency and difficulty incontrolling flashing. Further, compression molding may not be suitablefor certain types of parts, such as inserts with large heads.

In some embodiments, an insert with at least one hole can bemanufactured 1502, such as inserts described above. Once the insert ismanufactured, the insert can be situated so that a polymer can beinjection molded around the insert. For example, the insert can beplaced inside a cavity where molten polymer can flow around the insert,covering it such as embodiments of the above disclosure. Once the insertis properly located, a polymer diaphragm can be injection molded aroundthe insert 1504. A screw or ram plunger can be used to force moltenpolymer material into a cavity surrounding the insert. The polymerdiaphragm can fully encompass a portion of the insert, and can flow intoany holes in the insert. The use of at least one hole during injectionmolding can give better adhesion between the diaphragm and the insert.Further, the use of at least one hole can allow for a larger insert tobe used, due to the greater adhesion between the diaphragm and theinsert.

In some embodiments, the cavity can then be cooled 1506 to a temperaturewhere the polymer is solidified around the insert. This can be done by,for example, water cooling, ice cooling, or air cooling, and the methodof cooling does not limit the disclosure. In some embodiments, the actof injecting the polymer into the cavity can adequately cool thepolymer, and no further step need be taken, and step 1506 can beoptional.

As mentioned above, the use of a tapped hole and/or bonding holes canincrease the overall adhesion of the polymer diaphragm to the insert. Asshown in FIGS. 16A-C, the diaphragms described in the above prior arthave additional significant problems. FIG. 16A illustrates a insert 1602with a smooth or textured, such as sandblasted, surface 1604, such asthose described in the prior art. There are no holes, such as tapped orbonding holes, in the insert, unlike those described above. FIG. 16Billustrates the initial diaphragm assembly with the insert 1602 and thepolymer diaphragm 1606. The insert 1602 and the polymer diaphragm 1606meet at a surface 1608. When the polymer is injection molded, thepolymer will not adhere to the surface of the insert 1602. If aninjection molding was used, a gap 1610, as shown in FIG. 16C would formon the surface 1608 between the insert 1602 and the polymer diaphragm1606. This would lead to pumping inefficiencies, as well as eventualdiaphragm failure. In addition, a gap 1610 could result in a rubbingmotion between the diaphragm 1606 and the insert 1602. Rubbing can leadto abrasion and the formation of particulates, which could negativelyaffect the diaphragm assembly. Accordingly, injection molding has notbeen used for diaphragm assemblies of the prior art, and the abovedisclosure shows the advantageous use of injection molding with thedisclosed diaphragm assemblies.

From the foregoing description, it will be appreciated that an inventivecarbide alloy and method of manufacturing are disclosed. While severalcomponents, techniques and aspects have been described with a certaindegree of particularity, it is manifest that many changes can be made inthe specific designs, constructions and methodology herein abovedescribed without departing from the spirit and scope of thisdisclosure.

Certain features that are described in this disclosure in the context ofseparate implementations can also be implemented in combination in asingle implementation. Conversely, various features that are describedin the context of a single implementation can also be implemented inmultiple implementations separately or in any suitable subcombination.Moreover, although features may be described above as acting in certaincombinations, one or more features from a claimed combination can, insome cases, be excised from the combination, and the combination may beclaimed as any subcombination or variation of any subcombination.

Moreover, while methods may be depicted in the drawings or described inthe specification in a particular order, such methods need not beperformed in the particular order shown or in sequential order, and thatall methods need not be performed, to achieve desirable results. Othermethods that are not depicted or described can be incorporated in theexample methods and processes. For example, one or more additionalmethods can be performed before, after, simultaneously, or between anyof the described methods. Further, the methods may be rearranged orreordered in other implementations. Also, the separation of varioussystem components in the implementations described above should not beunderstood as requiring such separation in all implementations, and itshould be understood that the described components and systems cangenerally be integrated together in a single product or packaged intomultiple products. Additionally, other implementations are within thescope of this disclosure.

Conditional language, such as “can,” “could,” “might,” or “may,” unlessspecifically stated otherwise, or otherwise understood within thecontext as used, is generally intended to convey that certainembodiments include or do not include, certain features, elements,and/or steps. Thus, such conditional language is not generally intendedto imply that features, elements, and/or steps are in any way requiredfor one or more embodiments.

Conjunctive language such as the phrase “at least one of X, Y, and Z,”unless specifically stated otherwise, is otherwise understood with thecontext as used in general to convey that an item, term, etc. may beeither X, Y, or Z. Thus, such conjunctive language is not generallyintended to imply that certain embodiments require the presence of atleast one of X, at least one of Y, and at least one of Z.

Language of degree used herein, such as the terms “approximately,”“about,” “generally,” and “substantially” as used herein represent avalue, amount, or characteristic close to the stated value, amount, orcharacteristic that still performs a desired function or achieves adesired result. For example, the terms “approximately”, “about”,“generally,” and “substantially” may refer to an amount that is withinless than or equal to 10% of, within less than or equal to 5% of, withinless than or equal to 1% of, within less than or equal to 0.1% of, andwithin less than or equal to 0.01% of the stated amount.

Some embodiments have been described in connection with the accompanyingdrawings. The figures are drawn to scale, but such scale should not belimiting, since dimensions and proportions other than what are shown arecontemplated and are within the scope of the disclosed inventions.Distances, angles, etc. are merely illustrative and do not necessarilybear an exact relationship to actual dimensions and layout of thedevices illustrated. Components can be added, removed, and/orrearranged. Further, the disclosure herein of any particular feature,aspect, method, property, characteristic, quality, attribute, element,or the like in connection with various embodiments can be used in allother embodiments set forth herein. Additionally, it will be recognizedthat any methods described herein may be practiced using any devicesuitable for performing the recited steps.

While a number of embodiments and variations thereof have been describedin detail, other modifications and methods of using the same will beapparent to those of skill in the art. Accordingly, it should beunderstood that various applications, modifications, materials, andsubstitutions can be made of equivalents without departing from theunique and inventive disclosure herein or the scope of the claims.

What is claimed is:
 1. A method for manufacturing a diaphragm assemblycomprising: forming an insert having a head and a body, wherein the headis located at one end of the body; forming at least one interferencesurface on the insert; disposing the insert within a cavity configuredfor injection molding, wherein at least the head is completely disposedwithin the cavity; and injection molding a polymer onto the insert,wherein the polymer is configured to adhere to the head and the at leastone interference surface of the insert; wherein the polymer is a PVDFpolymer comprising 0.5% by weight natural PVDF and 99.5% by weight of aPVDF polymer having a density of 1.77 grams per cubic centimeter, awater absorption of 0.030%, a tensile yield strength of 6.50 MPa, anelongation at break of greater than 50%, an elongation at yield of 20%,a tensile modulus of 0.0800 GPa, a melting point of 101° C., adeflection temperature at 1.8 MPa of 46.0°, an oxygen index of 40%, anda melt viscosity in a range between 12.0 and 20.0 kilopoise when saidmelt viscosity is tested at 232° C. according to American Standard TestMethod D3835.
 2. The method of claim 1, wherein the head has a diametergreater than the diameter of the body.
 3. The method of claim 1, whereinforming the at least one interference surface comprises forming the atleast one interference surface at approximately the center of the headof the insert.
 4. The method of claim 1, wherein forming at least oneinterference surface comprising forming a plurality of interferencesurfaces on the head of the insert.
 5. The method of claim 1, whereinPTFE is not used.
 6. The method of claim 1, wherein forming the at leastone interference surface comprises tapping at least one hole into thehead of the insert to form a blind tapped hole.
 7. The method of claim3, wherein the forming the at least one interference surface furthercomprising forming at least four pairs of interference surfaces.
 8. Themethod of claim 1, wherein the at least one interference surface islocated on the outside of the head.
 9. The method of claim 8, whereinthe at least one interference surface comprises threads or grooves. 10.A two part diaphragm assembly comprising: an insert having a head and abody, wherein the head is located at one end of the body; at least oneinterference surface formed on the insert; and an injection-moldedpolymer diaphragm configured to at least partially surround the head ofthe insert and interfere with the at least one interference surface,wherein the polymer is a PVDF polymer comprising 0.5% by weight naturalPVDF and 99.5% by weight of a PVDF polymer having a density of 1.77grams per cubic centimeter, a water absorption of 0.030%, a tensileyield strength of 6.50 MPa, an elongation at break of greater than 50%,an elongation at yield of 20%, a tensile modulus of 0.0800 GPa, amelting point of 101° C., a deflection temperature at 1.8 MPa of 46.0°,an oxygen index of 40%, and a melt viscosity in a range between 12.0 and20.0 kilopoise when said melt viscosity is tested at 232° C. accordingto American Standard Test Method D3835.
 11. The assembly of claim 10,wherein the polymer is semi-transparent.
 12. The assembly of claim 10,wherein the polymer is transparent.
 13. The assembly of claim 10,wherein the at least one interference surface is located approximatelyat the center of the insert.
 14. The assembly of claim 10, wherein PTFEis not used.
 15. The assembly of claim 10, wherein the insert is metal.16. The assembly of claim 10, wherein the body of the insert comprises athread.
 17. The assembly of claim 10, wherein the at least oneinterference surface is a blind tapped hole.
 18. The assembly of claim10, wherein the insert further comprises at least one additionalinterference surface.
 19. The assembly of claim 18, wherein the at leastone additional interference surface is configured as a through holethrough the head.
 20. The assembly of claim 10, wherein the at least oneinterference surface comprises at least four pairs of interferencesurfaces.
 21. The assembly of claim 20, wherein the at least oneinterference surface comprises four holes approximately equally spacedaround the center of the insert and a fifth hole located at the centerof the insert.
 22. The assembly of claim 10, wherein the at least oneinterference surface extends into the body.
 23. The assembly of claim10, wherein the polymer diaphragm forms an air tight seal around theinsert.
 24. The assembly of claim 10, wherein the at least oneinterference surface has a rounded end.
 25. The assembly of claim 10,wherein the at least one interference surface is located on the outsideof the head.
 26. The assembly of claim 25, wherein the at least oneinterference surface comprises threads or grooves.
 27. A positivedisplacement pump comprising: an input channel; an output channel; and adiaphragm assembly located between the input and output channel andconfigured to translate liquid from the input channel to the outputchannel, the assembly comprising: an insert having a head and a body,wherein the head is located at one end of the body; at least oneinterference surface formed on the insert; and an injection-moldedpolymer diaphragm configured to at least partially surround the head ofthe insert and interfere with the at least one interference surface,wherein the polymer is a PVDF polymer comprising 0.5% by weight naturalPVDF and 99.5% by weight of a PVDF polymer having a density of 1.77grams per cubic centimeter, a water absorption of 0.030%, a tensileyield strength of 6.50 MPa, an elongation at break of greater than 50%,an elongation at yield of 20%, a tensile modulus of 0.0800 GPa, amelting point of 101° C., a deflection temperature at 1.8 MPa of 46.0°,an oxygen index of 40%, and a melt viscosity in a range between 12.0 and20.0 kilopoise when said melt viscosity is tested at 232° C. accordingto American Standard Test Method D3835.